Method for fabricating air gap adjacent to two sides of bit line

ABSTRACT

A method for fabricating semiconductor device includes the steps of: providing a substrate having a cell region and a peripheral region; forming a bit line structure on the cell region and a gate structure on the peripheral region; forming an interlayer dielectric (ILD) layer around the bit line structure and the gate structure; forming a conductive layer on the bit line structure; performing a first photo-etching process to remove part of the conductive layer for forming storage contacts adjacent two sides of the bit line structure and contact plugs adjacent to two sides of the gate structure; forming a first cap layer on the cell region and the peripheral region to cover the bit line structure and the gate structure; and performing a second photo-etching process to remove part of the first cap layer on the cell region.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 15/632,394filed Jun. 26, 2017, and incorporated herein by reference in itsentirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention relates to a method for fabricating semiconductor device,and more particularly to a method for fabricating air gap adjacent totwo sides of a bit line.

2. Description of the Prior Art

As electronic products develop toward the direction of miniaturization,the design of dynamic random access memory (DRAM) units also movestoward the direction of higher integration and higher density. Since thenature of a DRAM unit with buried gate structures has the advantage ofpossessing longer carrier channel length within a semiconductorsubstrate thereby reducing capacitor leakage, it has been gradually usedto replace conventional DRAM unit with planar gate structures.

Typically, a DRAM unit with buried gate structure includes a transistordevice and a charge storage element to receive electrical signals frombit lines and word lines. Nevertheless, current DRAM units with buriedgate structures still pose numerous problems due to limited fabricationcapability. Hence, how to effectively improve the performance andreliability of current DRAM device has become an important task in thisfield.

SUMMARY OF THE INVENTION

According to an embodiment of the present invention, a method forfabricating semiconductor device includes the steps of: providing asubstrate having a cell region and a peripheral region; forming a bitline structure on the cell region and a gate structure on the peripheralregion; forming an interlayer dielectric (ILD) layer around the bit linestructure and the gate structure; forming a conductive layer on the cellregion and the peripheral region; performing a first photo-etchingprocess to remove part of the conductive layer for forming storagecontacts adjacent two sides of the bit line structure and contact plugsadjacent to two sides of the gate structure; forming a first cap layeron the cell region and the peripheral region to cover the bit linestructure and the gate structure; and performing a second photo-etchingprocess to remove part of the first cap layer on the cell region.

According to another aspect of the present invention, a semiconductordevice includes: a substrate having a cell region and a peripheralregion; a bit line structure on the cell region; air gaps adjacent totwo sides of the bit line structure; a first cap layer on the bit linestructure and the air gaps, wherein the first cap layer is U-shaped; anda second cap layer on the first cap layer.

These and other objectives of the present invention will no doubt becomeobvious to those of ordinary skill in the art after reading thefollowing detailed description of the preferred embodiment that isillustrated in the various figures and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top view for fabricating a DRAM device according toan embodiment of the present invention.

FIG. 2 illustrates cross-section views of FIG. 1 along the sectionallines NN′ and OO′.

FIG. 3 illustrates cross-section views of FIG. 1 along the sectionallines AA′ and BB′.

FIG. 4 illustrates cross-sectional views of the process conducted afterFIG. 3.

FIG. 5 illustrates top views of the process conducted after FIG. 4.

FIG. 6 illustrates cross-section views of FIG. 5 along the sectionallines PP′ and QQ′.

FIG. 7 illustrates cross-section views of FIG. 5 along the sectionallines CC′ and DD′.

FIG. 8 illustrates cross-sectional views of the process conducted afterFIG. 7.

FIG. 9 illustrates top views of the process conducted after FIG. 8.

FIG. 10 illustrates cross-section views of FIG. 9 along the sectionallines EE′ and FF′.

FIG. 11 illustrates cross-section views of FIG. 9 along the sectionallines GG′, HH′ and II′.

FIG. 12 illustrates top views of the process conducted after FIG. 9.

FIG. 13 illustrates cross-section views of FIG. 12 along the sectionallines JJ′ and KK′.

FIG. 14 illustrates cross-section views of FIG. 12 along the sectionallines LL′ and MM′.

FIG. 15 illustrates a structural view of a semiconductor deviceaccording to an embodiment of the present invention.

DETAILED DESCRIPTION

Referring to FIGS. 1-15, FIGS. 1-15 illustrate a method for fabricatinga semiconductor device according to an embodiment of the presentinvention, in which FIG. 1 illustrates a top view for fabricating a DRAMdevice according to an embodiment of the present invention, the leftportion of FIG. 2 illustrates a cross-sectional view of FIG. 1 along thesectional line NN′, the right portion of FIG. 2 illustrates across-sectional view of FIG. 1 along the sectional line OO′, the leftportion of FIG. 3 illustrates a cross-sectional view of FIG. 1 along thesectional line AA′, and the right portion of FIG. 3 illustrates across-sectional view of FIG. 1 along the sectional line BB′. As shown inFIGS. 1-3, a substrate 12 is provided and a cell region 14 and aperipheral region 16 are defined on the substrate 12. Preferably, thesubstrate 12 is made of semiconductor material including but not limitedto for example a silicon substrate, an epitaxial substrate, a silicongermanium substrate, a silicon carbide substrate, or asilicon-on-insulator (SOI) substrate, but not limited thereto.

Next, bit line structures 18 are formed on the cell region 14 and a gatestructure 20 is formed on the peripheral region 16, and an interlayerdielectric (ILD) layer 22 is formed around the bit line structures 18and the gate structure 20. In this embodiment, word line structures (notshown), shallow trench isolations (STI) 24, and active region 26 couldbe formed in the substrate 12 under the bit line structures 18, in whichdoped region 28 and spacers 30 are formed adjacent to two sides of eachof the bit line structures 18 and each of the bit line structures 18includes an non-metal conductive layer 32, a selective barrier layer(not shown), a metal layer 34, and a hard mask 36. Preferably, thenon-metal conductive layer 32 includes polysilicon, amorphous silicon,or other silicon-containing or non-silicon conductive material, themetal layer 34 could include Al, W, Cu, Ti—Al alloy, or other lowresistance conductive material, and the hard mask 36 could include SiN,SiON, SiCN, or other insulating material.

Similar to the bit line structures 18, the gate structure 20 alsoincludes a non-metal conductive layer 32, a metal layer 34, and a hardmask 36. Moreover, a spacer 38 is disposed around the gate structure 20,a doped region or source/drain region (not shown) is disposed in thesubstrate 12 adjacent to two sides of the spacer 38, a CESL 40 isdisposed on the gate structure 20 and the spacer 38, and the ILD layer22 is disposed on the CESL 40.

Next, part of the ILD layer 22 on the cell region 14 and peripheralregion 16 could be removed to form contact holes 42 adjacent to twosides of the bit line structure 18 and contact holes 44 adjacent to twosides of the gate structure 20.

Next, as shown in FIG. 4, a conductive layer 46 is formed on the cellregion 14 and peripheral region 16 to fill the contact holes 42, 44 anda first photo-etching process is conducted to remove part of theconductive layer 46 to form storage contacts adjacent to two sides ofthe bit line structure 18 and contact plugs adjacent to two sides of thegate structure 20. Specifically in this embodiment, the firstphoto-etching process could be accomplished by first forming multiplepattern transfer material layers on the cell region 14 and peripheralregion 16, including sequentially forming an organic dielectric layer(ODL) 48, a silicon-containing hard mask bottom anti-reflective coating(SHB) 50, and a patterned resist 52 on the conductive layer 46.

Next, referring to FIGS. 5-7, in which FIG. 5 illustrates a top view ofthe process conducted after FIG. 4, the left portion of FIG. 6illustrates a cross-section of FIG. 5 along the sectional line PP′, theright portion of FIG. 6 illustrates a cross-section of FIG. 5 along thesectional line QQ′, the left portion of FIG. 7 illustrates across-section of FIG. 5 along the sectional line CC′, and the rightportion of FIG. 7 illustrates a cross-section of FIG. 5 along thesectional line DD′. As shown in FIGS. 5-7, an etching process isconducted by using the patterned resist 52 as mask to remove part of theSHB 50, part of the ODL 48, and part of the conductive layer 46 to formstorage contacts 54 adjacent to two sides of the bit line structure 18and contact plugs 56 adjacent to two sides of the gate structure 20. Theremaining patterned resist 52, SHB 50, and ODL 48 are removedthereafter.

It should be noted that the bit line structures 18 are disposed on thecell region 14 extending a long a first direction such as X-directionand the aforementioned first photo-etching process was also conductedalong the same first direction to remove part of the conductive layer 46on the cell region 14 to form storage contacts 54 between the bit linestructures 18. In other words, the direction of the first photo-etchingprocess is preferably parallel to the extending direction of the bitline structures 18.

Next, as shown in FIG. 8, a first cap layer 58 is formed on the cellregion 14 and peripheral region 16 to cover the bit line structures 18and the gate structure 20. In this embodiment, the first cap layer 58 ispreferably made of silicon nitride, but could also be made of otherdielectric material including but not limited to for example SiON orSiCN.

Next, referring to FIGS. 9-11, in which FIG. 9 illustrates a top view ofthe process conducted after FIG. 8, the left portion of FIG. 10illustrates a cross-section of FIG. 9 along the sectional line EE′, theright portion of FIG. 10 illustrates a cross-section of FIG. 9 along thesectional line FF′, the left portion of FIG. 11 illustrates across-section of FIG. 9 along the sectional line GG′, the middle portionof FIG. 11 illustrates a cross-section of FIG. 9 along the sectionalline HH′, and the right portion of FIG. 11 illustrates a cross-sectionof FIG. 9 along the sectional line II′. As shown in FIGS. 9-11, asection photo-etching process is conducted to remove part of the firstcap layer 58 and part of the storage contacts 54 on the cell region 14.In this embodiment, the second photo-etching process could beaccomplished by the same manner as the aforementioned firstphoto-etching process including sequentially forming a ODL, a SHB, and apatterned resist on the first cap layer 58 on cell region 14 andperipheral region 16.

Next, an etching process is conducted by using the patterned resist asmask to remove part of the SHB, part of the ODL, part of the first caplayer 58, and part of the storage contacts 54, and the remainingpatterned resist, SHB, and ODL are removed thereafter.

It should be noted that in contrast to the first photo-etching processof removing part of the conductive layer 46 on cell region 14 along thefirst direction to form storage contacts 54, the second photo-etchingprocess at this stage is conducted along a second direction orthogonalto the first direction, such as along Y-direction or the extendingdirection of the word line structures 64 to remove part of the first caplayer 58 and part of the storage contacts 54 on the cell region 14.

Specifically, such as shown on the left portion of FIG. 9, the secondphoto-etching process preferably removes part of the first cap layer 58and part of the storage contacts 54 on the cell region 14 along theY-direction so that the first cap layer 58 which was covering the entirecell region 14 now becomes rectangular stripes extending along theY-direction to intersect or cross with the bit line structures 18. Thestorage contacts 54 that were rectangular stripes extending along theX-direction now become square-shaped and first cap layer 58 is stilldisposed on top of each of the storage contacts 54.

Referring to FIGS. 12-14, in which FIG. 12 illustrates a top view of theprocess conducted after FIG. 9, the left portion of FIG. 13 illustratesa cross-section of FIG. 12 along the sectional line JJ′, the rightportion of FIG. 13 illustrates a cross-section of FIG. 12 along thesectional line KK′, the left portion of FIG. 14 illustrates across-section of FIG. 12 along the sectional line LL′, and the rightportion of FIG. 14 illustrates a cross-section of FIG. 12 along thesectional line MM′. As shown in FIGS. 12-14, an etching process is thenconducted by using the first cap layer on peripheral region 16 as maskto remove the ILD layer 22 adjacent to two sides of the bit linestructures 18 on cell region 14 for forming air gaps 60.

It should be noted that a wet etching process is preferably conducted atthis stage to remove part of the ILD layer 22 not covered by the firstcap layer 58 on the cell region 14, in which the etchant of the wetetching process first removes the ILD layer 22 not covered by the firstcap layer 58 and the removes the adjacent ILD layer 22 that was alreadycovered by the first cap layer 58, as shown by the cross-section viewextending along the sectional line MM′ in FIG. 12. In other words, airgaps 60 are formed adjacent to two sides of the bit line structures 18extending along the X-direction, in which part of the air gap 60 is notcovered by the first cap layer 58 while part of the air gap 60 iscovered by the first cap layer 58.

Referring to FIG. 15, the left portion of FIG. 15 illustrates across-section of the process conducted after FIG. 14 along the sectionalline MM′ and the right portion of FIG. 15 illustrates a cross-section ofthe process conducted after FIG. 13 along the sectional line KK′. Asshown in FIG. 15, a second cap layer 62 is then formed on the first caplayer 58 on the cell region 14 and peripheral region 16, and aplanarizing process such as chemical mechanical polishing (CMP) processis conducted to remove part of the second cap layer 62 and part of thefirst cap layer 58 and even part of the storage contacts 54 and part ofthe contact plugs 56 so that the top surfaces of the first cap layer 58and second cap layer 62 are even with the top surfaces of the storagecontacts 54 and contact plugs 56. Next, a storage capacitor could beformed on the cell region 14 to connect to the storage contacts 54. Thiscompletes the fabrication of a DRAM device according to an embodiment ofthe present invention.

Referring again to FIG. 15, FIG. 15 illustrates a structural view of asemiconductor device according to an embodiment of the presentinvention. As shown in FIG. 15, the semiconductor device includes a bitline structure 18 disposed on the cell region, air gaps 60 and storagecontacts 54 disposed adjacent to two sides of the bit line structure 18,a gate structure 20 disposed on the peripheral region 16, an ILD 22disposed on the gate structure 20 on the peripheral region 16, contactplugs 56 disposed adjacent to two sides of the gate structure 20 withinthe ILD layer 22, a first cap layer 58 disposed on the bit linestructure 18 and air gaps 60 on the cell region 14 and gate structure 20on the peripheral region 16, and a second cap layer 62 disposed on thefirst cap layer 58.

Viewing from a more detailed perspective, the first cap layer 58disposed between the storage contacts 54 on the cell region 14 isU-shaped, and the top surface of the storage contacts 54 is even withthe top surfaces of the first cap layer 58 and second cap layer 62.Preferably, the first cap layer 58 and the second cap layer 62 are madeof different material, in which the first cap layer 58 includes siliconnitride while the second cap layer 62 includes SiCN, but not limitedthereto. The storage contacts 54 and contact plugs 56 could be made ofsame material such as tungsten, but not limited thereto.

Those skilled in the art will readily observe that numerousmodifications and alterations of the device and method may be made whileretaining the teachings of the invention. Accordingly, the abovedisclosure should be construed as limited only by the metes and boundsof the appended claims.

What is claimed is:
 1. A method for fabricating semiconductor device, comprising: providing a substrate having a cell region and a peripheral region; forming a bit line structure on the cell region and a gate structure on the peripheral region; forming an interlayer dielectric (ILD) layer around the bit line structure and the gate structure; forming a conductive layer on the cell region and the peripheral region; performing a first photo-etching process to remove part of the conductive layer for forming storage contacts adjacent two sides of the bit line structure and contact plugs adjacent to two sides of the gate structure; forming a first cap layer on the cell region and the peripheral region to cover the bit line structure and the gate structure; and performing a second photo-etching process to remove part of the first cap layer on the cell region.
 2. The method of claim 1, wherein the bit line structure is disposed along a first direction on the cell region.
 3. The method of claim 2, further comprising performing the first photo-etching process to remove part of the conductive layer along the first direction for forming the storage contacts.
 4. The method of claim 1, further comprising performing the second photo-etching process to remove part of the first cap layer along a second direction.
 5. The method of claim 4, wherein the second direction is orthogonal to the first direction.
 6. The method of claim 1, further comprising removing part of the ILD layer adjacent to two sides of the bit line structure for forming air gaps after performing the second photo-etching process.
 7. The method of claim 6, wherein the first cap layer is on the bit line structure and the air gaps.
 8. The method of claim 7, wherein the first cap layer is U-shaped.
 9. The method of claim 1, further comprising forming a second cap layer on the cell region and the peripheral region.
 10. The method of claim 9, wherein the second cap layer and the first cap layer comprise a dielectric material.
 11. The method of claim 9, wherein the first cap layer and the second cap layer comprise different material.
 12. The method of claim 9, wherein the second cap layer comprises silicon carbon nitride (SiCN).
 13. The method of claim 1, wherein the first cap layer comprises silicon nitride.
 14. The method of claim 1, wherein the ILD layer comprises silicon oxide.
 15. The method of claim 1, wherein the storage contacts comprise tungsten.
 16. A method for fabricating semiconductor device, comprising: providing a substrate having a cell region and a peripheral region; forming a bit line structure on the cell region; forming air gaps adjacent to two sides of the bit line structure; forming a first cap layer on the bit line structure and the air gaps, wherein the first cap layer is U-shaped; and forming a second cap layer on the first cap layer, wherein the second cap layer and the first cap layer comprise a dielectric material.
 17. The method of claim 16, further comprising forming storage contacts adjacent to two sides of the bit line structure.
 18. The method of claim 17, wherein a top surface of the storage contacts is even with the top surfaces of the first cap layer and the second cap layer.
 19. The method of claim 16, wherein the first cap layer and the second cap layer comprise different material.
 20. The method of claim 16, further comprising: forming a gate structure on the peripheral region; forming an interlayer dielectric (ILD) layer on the gate structure; and forming contact plugs adjacent to two sides of the gate structure and within the ILD layer. 